New regulations encouraged weld plant update

The introduction of ADR 2003 Regulations and a decision to offer SS tanks introduced some interesting challenges to a tank fabrication department - met by updating welding equipment.

The introduction of ADR 2003 Regulations and a decision to offer SS tanks introduced some interesting challenges to the tank fabrication department.

Maidment Tanker Services, (Maidment) in Littlehampton, West Sussex, specialise in manufacturing road tanker vehicles for carrying petroleum spirits and fuel oils.

On the 10th May 2004 the UK adopted ADR 2003 Regulations following the introduction of the Carriage of Dangerous Goods and Use of Transportable Pressure Equipment Regulations 2004.

These new regulations dictated the design of all road tankers conveying dangerous goods, the consequence of which is that the tank shell material thickness will increase; they also introduce various other design restrictions and limitations.

Prior to the introduction of ADR all UK petroleum tankers were designed and manufactured in accordance with the UK Carriage of Dangerous Goods Regulations: Part 2.

Welding procedures and qualifications is another area governed by the new ADR regulations, with all personnel (tank welders) having to be individually assessed and coded to specific welding standards detailed in the new road tanker design code EN 13094.

Because these regulations were originally scheduled to come into force in 1999, Maidment Tanker Services were fully aware of the implications and what was required.

They introduced quality assurance and welding procedures in anticipation of the new regulations.

John Frost, Sales and Marketing Director at Kemppi (UK) explained: "Traditionally rigid tankers have been broadly manufactured from carbon steels with aluminium used to a lesser degree.

The introduction of the ADR Regulations demanded that road tanker manufacturers re-examine their design and construction techniques and in particular look closely at the type and thickness of materials used in the manufacture of road tankers.

The choice was straightforward, continue to manufacture in thicker mild steel, thus increasing the tank weight and reducing the payload capacity, or introduce new products manufactured from alternative materials.

Maidment made the strategic decision to offer mild steel and stainless steel, rejecting the option of aluminium as they believe it unsuitable for use on rigid chassis and will possibly result in higher maintenance and repair costs during the life of the tank.

Stainless steel tanks, whilst more expensive, provide the benefit of a lighter, more durable tank with the additional advantage of greater design flexibility under the new ADR design codes.

The introduction of ADR and Maidment's decision to offer stainless steel tanks introduced some interesting challenges to the tank fabrication department.

Not only would welding process and equipment need to change but also the working practice and construction techniques.

The Company knew investment was needed, particularly in welding technology.

Maidment's welding products supplier Rapid Welding and Industrial Supplies of Cosham, Hampshire was called in to assess their needs and recommended Kemppi's Pro Evolution 4200 Pulsed MIG welding equipment with Double Pulse technology including remote controlled KMP 400W water cooled 10m push-pull welding guns.

Kemppi's PRO Evolution with its 'slim line' design, is a digitally controlled, software based, modular welding system for MIG, Synergic MIG, Pulsed MIG, TIG, Pulsed TIG, MMA welding as well as carbon arc gouging, usable on all weldable materials including Mild steel, Stainless steel, Aluminium and more exotic materials such as CuSi3 and Duplex steel.

PRO Evolution has excellent power source performance for both peak currents (pulsed MIG) and duty cycles with IGBT inverter high internal control speed providing precision optimisation of the welding programs giving improved arc characteristics including stability, spatter free and quieter arc.

PRO Evolution multi functional power sources have high maximum currents and duty cycles.

With the PRO 4200 Evolution rated 420A at 100% duty cycle.

Kemppi and Rapid Welding technicians demonstrated the equipment to Maidment's directors, who then carefully evaluated the financial package from Andrew Doe, Rapid Welding Supplies Sales Manager and subsequently ordered four machines to undertake the construction of their first 10 tankers in stainless steel.

Maidment's Managing Director, Derek Mihell takes up the story: "The whole project has taken a couple of years and has been a great success.

Our welders are now fully coded to ADR EN 13094 requirements and have found the PRO Evolution 4200 easy to use, particularly with the addition of the push-pull welding guns and remote power trigger control.

This remote control has allowed us to stay inside the vessel during welding and no longer do we have to keep climbing in and out to adjust the settings on the machines.

Production of our first stainless steel Barrel using pulse welding took place over two years ago now and our welding engineers Les Brewer and Mark Mihell were certainly surprised by the speed of construction compared to the techniques previously used.

As a small to medium sized business we need to ensure our efficiency through investment like this.

On this occasion the new European legislation has had a positive effect on Maidment Tanker Services manufacturing efficiency and product quality as well as the expected life span of the Maidment product itself".

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